Active bolster

ABSTRACT

An active bolster for a vehicle is provided, wherein the bolster comprises an expansible hollow interior that is inflatable and is self-supporting in both an inflated and in an uninflated position. The bolster has an inflator module for inflating the expansible hollow interior. The bolster has an inner wall for projecting inwardly into the vehicle and away from the side of the vehicle on inflation of the expansible hollow interior. The bolster may have a relatively non-expansible component located between a first expansible chamber and a second expansible chamber. The bolster may comprise an outer wall having an attachment portion for attaching the outer wall to a portion of the side of the vehicle.

FIELD OF THE INVENTION

The present invention relates generally to protective devices as areoften installed in motor vehicles, such as automobiles, and, moreparticularly, the invention is directed to an inflatable bolster for usein a vehicle.

BACKGROUND OF THE INVENTION

Several types of device have been proposed for protecting vehicleoccupants during a crash event. Such devices can be categorized as beingeither passive devices or active devices.

Passive safety devices deform to absorb energy during a crash event.Passive devices, however, remain in a fixed position during a crashevent. Accordingly, there may be a relatively large distance over whichthe vehicle occupant may accelerate during a crash event beforeencountering a passive device.

Active safety devices are those that deploy immediately prior to a crashevent so that they are positioned relatively close to the vehicleoccupants. By reducing the distance between the occupant and the safetydevice, the occupant has less time to accelerate before encountering thesafety device, and therefore is less likely to sustain injury. A typicalactive safety device incorporates an air bag that inflates prior to acrash event. The air bag is typically a fabric bag that is held in ahousing until it is deployed. Air bag devices, however, add complexityand cost to the vehicular subassemblies to which they are added.

It would be advantageous to provide an active safety device that isrelatively inexpensive to incorporate into a vehicle.

SUMMARY OF THE INVENTION

In a first aspect, the invention is directed to an active bolster for avehicle, wherein the bolster includes a hollow main body that isinflatable and is self-supporting in both an inflated and in anuninflated position.

The main body may act directly as, or may have a covering that acts as,a first surface, which forms part of the visible interior of thevehicle.

The main body may replace a structural element of the vehicle, such as aheadrest on a vehicle seat, or an armrest on a vehicle door.

The main body may optionally include a vent means for ventingpressurized gas contained therein. The vent means may comprise one ormore holes of a selected size through the wall of the main body.Alternatively, the vent means may comprise a structure such as a reliefvalve.

In another aspect, the invention is directed to an inflatable devicepositioned on a rear-facing surface of a seat in a vehicle, in which theseat is positioned in front of a second seat. The inflatable device isinflatable for inflation during a vehicle crash event to protect anoccupant in the second seat.

In yet another aspect, the invention is directed to an inflatable lumbarbolster for inhibiting submarining of a seat-belted occupant in avehicle seat during a crash event.

In yet another aspect, the invention is directed to an inflatableforward pelvic bolster for inhibiting submarining of a seat-beltedoccupant in a vehicle seat during a crash event.

In yet another aspect, the invention is directed to a combination of aninflatable lumbar bolster and an inflatable forward pelvic bolster forinhibiting submarining of a seat-belted occupant in a vehicle seat.

In yet another aspect, the invention is directed to an inflatablearmrest for vehicle door.

In yet another aspect, the invention is directed to a device formounting on a door in a vehicle, wherein the device includes aninflatable bolster and an armrest. Wherein the inflatable bolsterincludes an inflatable, hollow main body. The hollow main body isself-supporting in both an uninflated position and an inflated position.The armrest is integrally connected with the main body portion.

In yet another aspect, the invention is directed to an inflatable deviceincluding a plurality of inflatable portions, which are fluidicallyconnected to a single inflator. For example, the inflatable portions maybe positioned for inflation above and below an armrest on a door.

In accordance with a first aspect of an embodiment of the invention,there is provided an inflatable side bolster for mounting on a side of avehicle. The inflatable side bolster comprises i) an expansible hollowinterior; ii) an inflator module for inflating the expansible hollowinterior; iii) an inner wall for projecting inwardly into the vehicleand away from the side of the vehicle on inflation of the expansiblehollow interior; and, iv) an outer wall located between the expansiblehollow interior and the side, the outer wall having an attachmentportion comprising at least one attachment for attaching the outer wallto a portion of the side of the vehicle, and a peripheral portionbordering the attachment portion. The outer wall is mountable to theportion of the side by the at least one attachment such that the outerwall remains attached to the portion of the side by the at least oneattachment during inflation, and the peripheral portion of the outerwall is free to move relative to the portion of the side of the vehicleto facilitate expansion of the expansible hollow interior duringinflation.

In accordance with a second aspect of an embodiment of the invention,there is provided a vehicle door comprising a window, a door bodyadjacent to the window portion, an armrest attached to the door body;and an inflatable bolster. The inflatable bolster comprises i) anexpansible hollow portion; ii) an inflator module for inflating theexpansible hollow portion; iii) an inner wall for projecting inwardlyinto the vehicle and away from the door on inflation of the expansiblehollow portion; iv) an outer wall located between the expansible hollowportion and the door body, the outer wall having an attachment portioncomprising at least one attachment for attaching the outer wall to aportion of the door, and a peripheral portion bordering the attachmentportion. The outer wall is mountable to the door body by the at leastone attachment such that the outer wall remains attached to the doorbody by the at least one attachment during inflation, and the peripheralportion of the outer wall is free to move relative to the door body tofacilitate expansion of the expansible hollow portion during inflation.

In accordance with a third aspect of an embodiment of the invention,there is provided an inflatable side bolster for a side of a vehicle,the inflatable side bolster comprising i) an expansible hollow interior;ii) an inflator module for inflating the expansible hollow interior;iii) an inner wall for projecting inwardly into the vehicle and awayfrom the side of the vehicle on inflation of the expansible hollowinterior; and, iv) an outer wall located between the expansible hollowinterior and the side, the outer wall having at least one attachment forattaching the outer wall to a portion of the side of the vehicle.

In accordance with a fourth aspect of an embodiment of the invention,there is provided a vehicle seat comprising a body-supporting surface, aback surface opposite to the body-supporting surface; and an inflatablebolster. The inflatable bolster comprises i) an expansible hollowportion; ii) an inflator module for inflating the expansible hollowportion; and, iii) an occupant-side wall for projecting away from theseat on inflation of the expansible hollow portion to displace at leastone of the body-supporting surface and the back surface.

In accordance with a fifth aspect of an embodiment of the invention,there is provided a vehicle floor bolster comprising i) an expansiblehollow portion; ii) an inflator module for inflating the expansiblehollow portion; and, iii) a foot-supporting surface for supporting apair of feet before inflation and for projecting upward on inflation ofthe expansible hollow portion to raise the pair of feet.

In accordance with a sixth aspect of an embodiment of the invention,there is provided a vehicle rollover bar bolster for mounting on avehicle rollover bar. The vehicle roll-over bar bolster comprises i) anexpansible hollow interior; ii) an inflator module for inflating theexpansible hollow interior; iii) a radially outer wall for projectingoutwardly away from the vehicle roll-over bar on inflation of theexpansible hollow interior; and, iv) a radially inner wall forattachment to the vehicle rollover bar, the radially inner wall beinglocated between the expansible hollow interior and the vehicle rolloverbar.

In accordance with a seventh aspect of an embodiment of the invention,there is provided a vehicle roof bolster comprising i) an expansiblehollow portion; ii) an inflator module for inflating the expansiblehollow portion; and, iii) a roof surface for projecting away from avehicle roof on inflation of the expansible hollow portion.

In accordance with a eighth aspect of an embodiment of the invention,there is provided a vehicle pillar bolster comprising i) an expansiblehollow portion; ii) an inflator module for inflating the expansiblehollow portion; and, iii) a pillar surface for projecting into thevehicle on inflation of the expansible hollow portion.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described by way of example only withreference to the attached drawings, in which:

FIG. 1A is a perspective view of an active bolster in accordance with afirst embodiment of the present invention, mounted on a door of avehicle below the armrest, and in an uninflated position;

FIG. 1B is a perspective view of the active bolster shown in FIG. 1A inan inflated position;

FIG. 1C is a sectional side view of the bolster in the uninflatedposition shown in FIG. 1A;

FIG. 1D is a sectional side view of the bolster in the inflated positionshown in FIG. 1B;

FIG. 2A is a sectional side view of an active bolster in accordance withanother embodiment of the present invention, in an uninflated position;

FIG. 2B is a sectional side view of the bolster shown in FIG. 2A, in aninflated position;

FIGS. 3A and 3B are perspective views of a bolster mounted on a vehicledoor above the armrest, in accordance with yet another embodiment of thepresent invention;

FIGS. 4A and 4B are perspective views of a bolster and armrestintegrally connected together in accordance with another embodiment ofthe present invention;

FIGS. 5A and 5B are perspective views of an armrest-mounted bolster inaccordance with yet another embodiment of the present invention;

FIGS. 6A and 6B are perspective views of a headrest-mounted bolster inaccordance with yet another embodiment of the present invention;

FIGS. 7A and 7B are perspective views of a headrest-mounted bolster incombination with a neck bolster, in accordance with yet anotherembodiment of the present invention;

FIGS. 8A and 8B are perspective views of a lumbar bolster in combinationwith a forward pelvic bolster, in accordance with yet another embodimentof the present invention;

FIGS. 9A and 9B are perspective views of a seat-mounted bolster, inaccordance with yet another embodiment of the present invention;

FIGS. 10A and 10B are perspective views of a bolster mounted on the rearface of a seat, in accordance with yet another embodiment of the presentinvention;

FIGS. 11A and 11B are perspective views of a floor pan-mounted bolster,in accordance with yet another embodiment of the present invention;

FIGS. 12A and 12B are perspective views of a bolster mounted on both thefloor pan and the toe pan, in accordance with yet another embodiment ofthe present invention;

FIGS. 13A and 13B are perspective views of a bolster mounted on rolloverprotection bars on a vehicle, in accordance with yet another embodimentof the present invention;

FIG. 13C is a sectional side view of a bolster and a rollover protectionbar shown in FIG. 13A;

FIGS. 14A and 14B are perspective views of a roof-mounted bolster inaccordance with yet another embodiment of the present invention;

FIGS. 15A and 15B are perspective views of a pillar-mounted bolster inaccordance with yet another embodiment of the present invention;

FIG. 16A is an elevation view of a bolster in accordance with yetanother embodiment of the present invention, in an uninflated condition;

FIG. 16B is a side view of the bolster shown in FIG. 16A, in anuninflated condition, near an armrest;

FIG. 16C is a side view of the bolster shown in FIG. 16A, in an inflatedcondition, near an armrest;

FIG. 16D is a perspective view of the bolster shown in FIG. 16A in aninflated condition;

FIG. 16E is a front view of an active side bolster in accordance with afurther embodiment of the invention in an uninflated condition,positioned in an interior door panel;

FIG. 16F is a front view of the outside of the bolster shown in FIG. 16Ein an uninflated condition, positioned in an interior door panel;

FIG. 16G is a front view of the outside of the bolster shown in FIG. 16Ein an uninflated condition, positioned in an interior door panel, withdoor sheet metal shown in the foreground;

FIG. 16H is a side view of the bolster shown in 16E in an uninflatedcondition, positioned in an interior door panel;

FIG. 16I is a side view of the bolster shown in 16E in an inflatedcondition, positioned in an interior door panel;

FIG. 17A is a side view of a connection between the inflatable body andthe gas channel as contained in the bolster shown in FIG. 16E inaccordance with a further embodiment of the invention;

FIG. 17B is a perspective view of the connection shown in FIG. 17A;

FIG. 18A is a side view of an alternative connection between theinflatable body and the gas channel as contained in the bolster shown inFIG. 16E in accordance with a further embodiment of the invention;

FIG. 18B is a perspective view of the connection shown in FIG. 18A;

FIGS. 19A, 19B and 19C show sectional and perspective side views ofalternative means to fasten and secure an embodiment of an active sidebolster to a vehicle support structure;

FIG. 20A is a perspective view of a headrest bolster in accordance witha further embodiment of the invention in an un-inflated configuration;

FIG. 20B is an exploded view of the bolster shown in FIG. 20A;

FIG. 20C is an assembled perspective view of the bolster shown in FIG.20A covered with a headrest cover in an un-inflated configuration;

FIG. 20D is an assembled perspective view of the bolster shown in FIG.20C in an inflated configuration;

FIG. 21A is an exploded view of a seat back mounted bolster, inaccordance with a further embodiment of the invention, shown in anun-inflated configuration;

FIG. 21B is a perspective view of the bolster shown in FIG. 21A shown inan un-inflated configuration;

FIG. 21C is a sectioned view of the bolster shown in FIG. 21A shown inan un-inflated configuration;

FIG. 21D is a perspective assembled view of the bolster shown in FIG.21A shown in an un-inflated configuration; and

FIG. 21E is a perspective assembled view of the bolster shown in FIG.21A shown in an inflated configuration.

DETAILED DESCRIPTION OF THE INVENTION

Examples of inflatable bolsters include the structures illustrated inU.S. Pat. Nos. 6,032,978, 6,203,057, and 6,578,867, the entire contentsof which are incorporated herein by reference.

Reference is made to FIGS. 1A, 1B, 1C and 1D, which illustrate an activebolster 10 in accordance with a first embodiment of the presentinvention. The active bolster 10 is positioned on a door 17 of a vehicle15, and deploys to protect a vehicle occupant 13 (see FIG. 1C) during acrash event and in particular during a side impact incurred by thevehicle 15 (see FIG. 1A). The vehicle 15 may be any applicable vehicle,such as an automobile, an SUV (sport-utility vehicle), or a pick-uptruck. The active bolster 10 can be configured to absorb energy toprotect the upper torso, thorax, lower torso, head or combinations ofthese regions of the occupant 13 (FIG. 1C) during a crash event.

Referring to FIG. 1C, the bolster 10 includes a hollow main body 11 andan attachment means 21. The hollow main body 11 is inflatable and isself-supporting in both an inflated position (FIG. 1C) and in anuninflated position (FIG. 1D). The main body 11 has an outside wall 12,an inside wall 14 and a side wall 16 that connects the outside andinside walls 12 and 14. The outside wall 12 of the bolster 10 is thewall that faces towards the outside of the vehicle 15. In the embodimentshown in FIGS. 1A-1D, the outside wall 12 is captured by the attachmentmeans 21.

The inside wall 14 is the wall that faces the interior of the vehicle15. In the bolster's folded state, as shown in FIGS. 1A and 1C, theinside wall 14 may form part of the interior door panel 19 of thevehicle 15. In such a case, the inside wall 14 may be provided with asuitable finish, e.g., in accordance with the design theme for the restof the vehicle interior. Thus, the inside wall 14 may act as a firstsurface, i.e., a surface that is directly exposed to view by a vehicleoccupant 13.

Alternatively, a suitable interior door panel segment, such as a fabricpanel, may be attached to the inside wall 14. Thus, the inside wall 14can act as a support for holding a door panel segment, thereby replacingthe support that would have been required in the absence of the bolster10.

The hollow main body 11 includes one or more pleats 18 thereon, whichmay be positioned around the sidewall 16, as shown in FIGS. 1C and 1D.The pleats 18 permit the expansion of the hollow main body 11 upon theintroduction of a pressurized gas therein. The number, stiffness andposition of the pleats 18 can be selected depending upon the selecteddirection of expansion of the bolster 10. The pleats 18 may beconfigured to control the amount and direction of expansion of the mainbody 11, so that the inside wall 14, and the overall body 11, may bepositioned in a selected position relative to the vehicle occupant 13 toprovide selected energy absorption for selected regions of theoccupant's body.

The pleats 18 need not be positioned on the sidewall 16. For example,referring to FIGS. 2A and 2B, the pleats 18 may be provided on theinside wall 14. In the case where they are provided on the inside wall14, it may be desirable for aesthetic reasons for the inside wall 14 tobe covered by a suitable interior door panel segment 19 a to hide thepleats 18 from view by the vehicle occupants.

The pleats 18 may be created as U-shaped portions that extend betweenridges on the main body 11.

As another alternative, the main body 11 may be provided with a selectedshape and may be folded or otherwise put into its uninflated position.The body 11 may be folded over on itself whereby at least some of thefolds do not constitute pleats.

It is alternatively possible to incorporate other means for controllingthe direction and degree of expansion that occurs for the main body 11.For example, one or more tethers (not shown) may be provided, eachtether connecting between a point on the main body 11 and a structuralmember on the vehicle 15. Such tethers could work optionally incombination with pleats on the main body 11.

As another alternative, the main body 11 may have a wall thickness thatvaries over its surface. The main body 11 may be provided with arelatively thinner wall where expansion is desired, and may be providedwith a relatively thicker wall where expansion is to be inhibited. Bycontrolling the positions of the regions of thicker and thinner walls,the degree and direction of expansion may be controlled for the mainbody 11. In such an embodiment, it will be appreciated that expansion ofthe main body 11 will occur as a result of plastic deformation of thewall, in particular where the wall is relatively thinner. It will beappreciated, however, that some plastic deformation will take placeduring expansion for embodiments incorporating pleats 18.

Other means for controlling the direction and degree of expansion of themain body 11 may alternatively be employed either alone or incombination with each other and with those described above. For example,tabs (not shown) may be provided at selected points on the main body 11,which engage the vehicle structure. Such engagement could be used to fixthe position of one part of the main body 11 while permitting expansionin another part of the main body 11, thereby causing the main body 11 toexpand around a corner, for example. Such tabs may be made to break awayat a selected level of force. Alternatively, hinges may be providedinstead of tabs, depending on the specific application.

The hollow body 11 is preferably made from a polymeric material such asa polypropylene-based material. The main body 11 may be formed of ablow-molded polypropylene-based or other polyolefin material. Thematerial of construction may be a recyclable material. It is optionallypossible that different portions of the main body 11 may be made fromdifferent materials. It is further possible that such use of differentmaterials, may be used to assist in controlling the deployment patternof the main body 11. Using a thermoplastic for the bolster 10 providesflexibility for matching vehicle interior designs.

An inflation means (not shown) is provided for inflating the main body11. Generally, the inflation means will include a source of inflatinggas, typical of those used in vehicle air bags. This will be connectedto an activation source. Advantageously, the bolster 10 may bemanufactured in a plastic blow molding operation. The blow moldingoperation is particularly convenient for making closed, hollow articles.The hollow body 11 defines an internal chamber, which may be a closedchamber. If the chamber is a closed chamber, then the chamber mayconfine the expanding gas sufficiently to cause expansion of the hollowmain body 11 upon activation without the need for an internal bladder.Optionally, the inflatable bolster 10 can include an internal bladder,in which case the chamber need not be sufficiently gas tight. If aninternal bladder is provided, then preferably the outside wall 14 willinclude access means to position the appropriate bladder within thechamber and to position the means for supplying the pressurized gas tothe bladder upon activation.

Referring to FIGS. 1C and 1D, the hollow body 11 includes an inlet 20for receiving the inflation gas. The inflation gas may be provided byany suitable inflation device, such as an inflators used on air bagsystems. If the bolster 10 includes multiple chambers therein, the inlet20 may branch into several internal conduits, each of which connects theinlet to an internal chamber.

The hollow body 11 may optionally include a venting means 22. Theventing means 22 limits pressure build up within the main body 11 duringbolster deployment and provides a selected force/pressure behavior forthe bolster 10 during deployment and occupant impact with the bolster10. The venting means 22 can be used to provide a slower (ie. lessabrupt) deceleration for the occupant 13, subsequent to impact betweenthe occupant 13 and the bolter 10, thereby reducing the likelihood ofinjury to the occupant 13. Additionally, after deployment of the bolster10, the venting means 22 permits the main body 11 to deflate to providespace for the occupant 13 to move around or egress the vehicle 15.

The venting means 22 may be, for example, one or more vent holes 24, asshown, or may alternatively be some other suitable venting means, suchas a relief valve (not shown). In an embodiment where vent holes 24 areutilized, the vent holes 24 are made adequately small to permit thebuild up of pressure in the main body 11 to cause it to expand duringdeployment of the bolster 10.

The attachment means 21 are used to attach the bolster 10 to the vehiclestructure. The attachment means 21 may comprise a support member 23,which has mounting tabs 25 thereon. The support member 23 captures theoutside wall 12 and a portion of the sidewall 16. The mounting tabs 25may include fastener apertures (not shown) so that fasteners (not shown)may be used to removably mount the bolster 10 to the vehicle structure.This permits the bolster 10 to easily be removed and replaced whenappropriate. By capturing the outside wall 12, the support member 21prevents expansion of the hollow body 11 towards the outside of thevehicle 15, so that when the main body 11 is inflated, expansion of themain body 11 occurs towards the interior of the vehicle 15. The supportmember 21 and tabs 23 may be metallic, or may be made from a polymericmaterial, depending on the forces expected to be incurred and the roomavailable.

It is alternatively possible to have the mounting tabs 23 be formeddirectly on the main body 11. For example, the entire outside end of themain body 11 could be made suitable thick-walled for strength and forresistance to outwardly directed expansion during inflation. The tabs 23could be formed directly thereon during a molding process.

The fasteners used to attach the bolster 10 to the vehicle structure mayinclude trim clips, rivets, screws or other mechanical fasteners, oralternatively adhesive, depending on the application.

The bolster 10 is shown as being mounted on the door 17 below thearmrest, shown at 26. During a crash event, pressurized air (or anysuitable pressurized gas) is introduced into the hollow main body 11from the inflator through the inlet 20. The pressurized gas causes themain body 11 to expand. In the embodiment shown in FIGS. 1A-1D, the mainbody 11 is configured to expand directly inwardly into the interior ofthe vehicle 15, towards the upper legs and hip region of the vehicleoccupant 13 seated in the seat 28 adjacent the door 17. In this way, ifthe vehicle occupant 13 is accelerated by the crash event towards thedoor 17, he/she will encounter the bolster 10 earlier than he/she wouldhave encountered the door 17, had the bolster 10 not been present. As aresult, the occupant 13 will have reached a lower velocity whenencountering the bolster 10 than he/she would have reached if he/she hadbeen free to accelerate all the way to the door 17. Additionally, thebolster 10 provides the occupant 13 with a greater distance over whichto decelerate. As a result of the lower velocity and the greaterdeceleration distance, the occupant 13 is less likely to sustain injuryfrom the crash event. If the bolster 10 is provided with the vent means22, the deceleration can be even better controlled, and the occupant 13can be at even lower risk of sustaining injury from the crash event.

Reference is made to FIGS. 3A and 3B, in which the bolster 10 is shownas being mounted to the door 17 above the armrest 26. In thisembodiment, the bolster 10 may be configured to extend inwardly into theinterior of the vehicle 15 towards the occupant 13 and to present aninflated form that engages the upper torso, ie. the shoulder region, ofthe occupant 13, protecting the occupant from collision with both thedoor body, shown at 17 b and the lower region of the door window. Thedoor window is shown at 17 a.

In a crash event, the shoulder region of an occupant 13 may move farthertowards the vehicle door 17 than the hip region of the occupant 13 does,since the shoulder region may be less securely held in place by a seatbelt than the hip region. Thus, while protecting the hip region of theoccupant 13 is valuable, it is also valuable to protect the shoulderregion of the occupant 13 from colliding with the door 17. The bolster10 shown in FIGS. 3A and 3B accomplish this. Additionally, by deployingto protect the shoulder region of the occupant 13, the bolster 10 inFIGS. 3A and 3B also protects the head of the occupant 13 by making itless likely that the head of the occupant will collide with the door 17.

Reference is made to FIGS. 4A and 4B, in which the bolster 10 is shownas being positioned aft of the armrest 26. In this position, the bolster10 can cover a relatively large vertical stretch along the door body 17b, without interference from the armrest 26. The bolster 10 could beconfigured to cover substantially the entire distance between the top ofthe door body 17 b, and the seat bottom portion, shown at 28 a. Thebolster 10 can be configured to extend directly inwardly towards theoccupant 13 and thereby protect a relatively large portion of theoccupant's torso.

Reference is made to FIGS. 16A, 16B, 16C and 16D, which show the bolster10 including a first bolster portion 50 and a second bolster portion 52.The first and second bolster portions 50 and 52 are fluidicallyconnected to an inflator, shown at 54, by fluid conduits 55 a and 55 b.Thus, in this embodiment, the bolster 10 includes two separateinflatable bolster portions 50 and 52, both of which are inflated by asingle gas inflator 54. The outer wall 12 of the bolster portions 50 and52 comprise peripheral portions 72, which extend relative to the doorduring inflation. This is advantageous in that the assembly may be lessexpensive than two separate bolster assemblies and two separateinflators. The bolster portions 50 and 52 are shown in their uninflatedcondition in FIGS. 16A and 16B, and are shown in their inflatedcondition in FIGS. 16C and 16D.

Additionally, it will be noted that dividing the bolster 10 into thefirst and second bolster portions 50 and 52 which are inflated by acommon inflator 54, permits the bolster 10 to cover substantially all ofthe height of the door body (not shown in FIGS. 16A, 16B, 16C and 16D)above and below the armrest 26 (shown in FIGS. 16B and 16C), whileavoiding pushing the armrest 26 itself into the interior of the vehicle.To facilitate this, the bolster 10 may be made relatively stiffer anduninflatable in the region 56 of the bolster 10 that is proximate thearmrest 26. Stiffening the region 56 inhibits the bolster 10 from urgingthe armrest 26 into the vehicle interior during inflation of the bolster10. Additionally, mounting plates 58 and 60 may be provided in thestiffened region 56, which contain mounting apertures 62, 64, 66 and 68,which are used to mount the bolster 10 to the vehicle's structure.Mounting the bolster 10 in the region 58 that is proximate the armrest26 further assists in inhibiting the bolster 10 from urging the armrest26 into the vehicle interior during bolster inflation. The mountingplates 58 and 60 may be made from any suitable material, such as apolymeric material that can be joined to the rest of the bolster 10 withsuitable structural integrity.

Referring to FIG. 16E, there is illustrated in a front view an exposedinterior door panel 19 showing side bolster 10 comprising the first 50and second 52 bolster portions in accordance with a further embodimentof the invention. The bolster portions 50 and 52 are shown positioned inrelation to the armrest 26 and a detachable interior panel portion 51 ofthe exposed interior door panel 19. The detachable interior panelportion 51 can be released from the door panel 19 by the inflation ofthe second bolster portion 52. For clarity, analogous elements betweenside bolster 10 of FIGS. 16A-16D, and side bolster 10 of FIGS. 16E-16I,are denoted by the same numerals. In FIGS. 16E and 16F, the bolsterportions 50 and 52 are shown in their un-inflated condition.

Referring to FIG. 16F, the unexposed side of the interior door panel isshown in an interior view, and the side bolster 10 is shown with thefirst bolster portion 50 and the second bolster portion 52 positionedabove and below the armrest 26 respectively. The inflator 54 ispositioned close to the armrest 26, and the connection 71 between thefluid conduit 55 a and the first bolster portion 50 is shown. Arelatively non-expansive attachment portion 61, including mountingplates 58 and 60, and mounting apertures 62, 64, 66 and 68 is alsoshown. The required strength and stiffness of the attachment portion 61may be obtained by increasing the thickness of the wall surrounding thehollow interior of the attachment portion 61 appropriately to resistdeformation due to the increased air pressure within the hollow interiorthat causes inflation of the bolster portions 50 and 52. The hollowinterior of attachment portion 61 also houses the inflator module 54,which inflates both the first 50 and second 52 bolster portions. Theattachment portion 61 is bordered by a peripheral portion 72.

The first 50 and second 52 bolster portions are fluidly connected to theinflator module 54 by fluid conduits 55 a and 55 b respectively. Thejunction 55 c between fluid conduits 55 a and 55 b comprises a “V”shaped hollow interior. The relative proportions and orientation of the“V” shaped junction 55 c are designed to direct an appropriate portionof the inflation gas into the first 50 and second 52 bolster portions toensure proper inflation. The outer wall 12 of each bolster portion 50,52contains pleats 18 to allow for the peripheral portion of the outer wall12 of the bolster portions 50,52 to extend relative to the door duringinflation.

The first 50 and second 52 bolster portions may include a vent hole 24.A vent hole 24 limits the pressure build up within the bolster 10 duringdeployment and provides a selected force/pressure behaviour for thebolster 10 during deployment. A vent hole 24 can be used to provide aslower deceleration for the vehicle occupant, subsequent to contactbetween the occupant and the bolster 10, thereby reducing the likelihoodof injury to the occupant. Additionally, a vent hole 24 may permit thefirst 50 and second 52 bolster portions to deflate after deployment toprovide space for the occupant to egress the vehicle. A vent hole 24 maybe made adequately small to permit the build up of pressure within thebolster 10 to cause it to expand properly during impact.

Referring to FIG. 16G, the interior side of the door panel 19 a and thesecond bolster portion 52 are shown with the door panel metal supportstructure 70 in the foreground. The metal support structure 70 has aportion cut away to illustrate the location of the inflator 54 andsecond bolster portion 52 pleats 18 and the relative position of themounting plate 60 and mounting apertures 66 and 68 with respect to thedoor panel metal support structure 70.

Referring to FIG. 16H, the first 50 and second 52 bolster portions areshown in a side view in relation to the vehicle door body 17 b, thevehicle door window 17 a, the interior door panel 19, the armrest 26,and the detachable interior panel portion 51. The first 50 and second 52bolster portions are shown in an un-inflated condition. In thiscondition, expansible hollow interior 57 of each bolster portion 50, 52is uninflated.

Referring to FIG. 16I, the side view of the side bolster 10 of FIG. 16His repeated, with the side bolster shown in the inflated condition. Asshown, both the first bolster portion 50 and the second bolster portion52 can deploy into the vehicle interior around the armrest 26 to protectthe shoulder and pelvic regions of the vehicle occupants 13respectively. The detachable interior door panel 51 can be displaced, asshown in FIG. 16I by the inflation of the expansible hollow portion 57of the second bolster portion 52. The expansion of the bolster portions50, 52 involves movement of the inside wall 14 into the vehicle'sinterior and movement of the peripheral portion of the outside wall 12away from the vehicle door body 17 b and window 17 a. The peripheralportion of the outside wall 12 may also extend along the dimension ofthe door body, so that, for example, bolster portion 50 may partly coverthe window. The direction and extent of this displacement is affected bythe design and number of pleats 18 contained in the outside wall 12 ofthe bolster.

The exposed surface of both the first bolster portion 50 and the secondbolster portion 52 can be finished or covered suitably to act as anormal exposed surface or first surface in door-mounted embodiments,such as the embodiment shown in FIGS. 16E, 16F, 16G, 16H and 16I.

As described above, the side bolster 10 comprises an expansible hollowinterior 57, an inflator 54 for inflating the expansible hollow interior57, and an inside wall 14 or first wall for projecting inwardly into thevehicle and away from the sides of the vehicle on inflation of theexpansible hollow interior 57 to protect the vehicular occupants 13.

Reference is made to FIG. 17A, which shows a sectioned side view of asnap-in connection 71 a used between the fluid conduit 55 a and theoutside wall 12 of a bolster portion 50 in an embodiment of theinvention. During assembly, the opening of the fluid conduit 55 a isaligned with the appropriately sized opening in the outside wall 12 ofthe first bolster portion 50. External pressure is then applied to thefluid conduit 55 a forcing the conduit into the bolster portion 50. Theangled shape of the fluid conduit tabs 69 allow for the conduit to berelatively easily inserted into the outside wall of the bolster portion50, but create significant resistance preventing the conduit fromsubsequently being removed from the outside wall 12 of the bolsterportion 50. Once installed, the fluid conduit 55 a creates fluidcommunication between the inflator 54 (not shown in FIG. 17A or 17B) andthe expansible hollow interior 57 of the bolster portion 50. Theconnection 71 a between the fluid conduit 55 a and the outside wall 12of the bolster portion 50 is surrounded by expansion pleats 18 whichfacilitate movement and inflation of the bolster portion 50. Referringto FIG. 17B, the embodiment of the snap-in connection 71 a is shown in asectioned perspective view relative to the fluid conduit 55 a and theoutside wall 12 of a bolster portion 50.

FIGS. 18A and 18B show an alternate means for attaching the fluidconduit 55 a to the outside wall 12 of the bolster portion 50 to createa fluid connection 71 b between the inflator 54 (not shown in FIGS. 18Aand 18B) and the expansible hollow interior 57 of the bolster portion50. Reference is made to FIG. 18A, which shows a sectioned side view ofa ferrule and gear clamp connection 71 b used between the fluid conduit55 a and the first bolster portion 50 in an embodiment of the invention.The ferrule and gear clamp connection 71 b is an alternate means ofsecuring the fluid conduit 55 a to the bolster portion 50 to the meansshown in FIGS. 17A and 17B. Referring to FIG. 18B, the embodiment of theferrule and gear clamp connection 71 b is shown in a perspective view.This view shows the relative positions of the fluid conduit 55 a, theoutside wall 12 of the first bolster portion 50, and the expansionpleats 18.

Reference is made to FIG. 19A which shows a means to fasten a particularembodiment of the bolster 10 to the door panel metal support structure70 in accordance with an embodiment of the invention. In thisembodiment, the outside wall 12 of the bolster 10 comprises integralbolster mounting tabs 74, which are of an appropriate thickness andheight to provide the required tensile strength and other desiredmechanical properties to secure the bolster 10 to the structure 70 bothbefore and during inflation. The integral bolster mounting tabs arepositioned within the attachment portion 61, between the pleats 18 onthe outer wall 12 of the bolster 10 and the connection 71 between thebolster 10 and the fluid conduit 55 a. The connections between thebolster 10 and the door panel metal support structure 70 within theattachment portion 61 of the bolster outer wall 12 remain in placeduring inflation of the expansible chamber 57. Additional frangiblefasteners (not shown) may be used to detachably attach any of theperipheral portions 72 of the outer wall 12 of the bolster, includingthe expansion pleats 18, to the door panel metal support structure 70while the bolster is in its uninflated configuration. Fasteners withinthe peripheral portions 72 of the bolster outer wall 12 can be releasedby inflation of the expansible chamber 57 so as to not prevent the outerwall 12 from moving relative to the side of the vehicle duringinflation.

The particular attachment means shown in FIG. 19A comprises fasteningclips 75 that are placed over the integral bolster mount tabs 74. Thefastening clips 75 are affixed to the integral bolster mounting tabs 74by rivets 76. This design is advantageous in that the integral bolstermounting tabs 74 are formed during the initial molding of the bolster 10and the fastening clips 75 can be manufactured separately and theneasily affixed to the bolster 10 via the rivets 76 prior to the bolster10 being installed in the vehicle. Upon affixing the required fasteningclips 75 to the integral bolster mounting tabs 74, the bolster can bepositioned relative to the door panel metal support structure 70 andaligned with the predetermined fastening locations 63 within saidstructure. With the fastening clips 75 properly aligned with thefastening locations 63, pressure can be applied to the bolster portion50 forcing the fastening clips 75 into the fastening locations 63 andcreating a snap-fit connection between the outer wall 12 of the bolster10 and the door panel metal support structure 70. This connection meanscan be implemented at the appropriate number of fastening locations 63as required to produce the desired strength of mechanical connectionbetween the bolster 10 and the door panel metal support structure 70.

Reference is made to FIG. 19B, which shows another embodiment of a meansto fasten the outer wall 12 of an expansible chamber 57 to the doorpanel metal support structure 70. In this embodiment, the outside wall12 of the active support bolster 10 comprises insert apertures 59appropriately sized to receive mounting stud inserts 77, which are of anappropriate thickness and size to provide the required tensile strengthand other desired mechanical properties. The insert apertures 59 arepositioned within the attachment portion 61, between the expansionpleats 18 on the outer wall 12 of the bolster 10 and the connection 71between the expansible chamber 57 and the fluid conduit 55 a. Additionalfrangible fasteners (not shown) may be used to detachably attach any ofthe peripheral portions 72 of the outer wall 12 of the bolster,including the expansion pleats 18, to the door panel metal supportstructure 70 while the bolster is in its uninflated condition. Fastenerswithin the peripheral portions 72 of the bolster outer wall 12 can bereleased by inflation of the expansible chamber 57 so as to not preventthe outer wall 12 from moving relative to the side of the vehicle duringinflation.

The particular attachment means embodied in FIG. 19B comprises mountingstud inserts 77 that are secured in the bolster 10 and inserted throughthe fastening locations 63 in the door panel metal support structure 70.Fastening nuts 78, with a diameter appropriately larger than that of thefastening location openings 63, are then threaded onto the studs andtightened until the desired level of mechanical compression is achieved.This connection means can be implemented at the appropriate number offastening locations 63 as required to produce the desired strength ofmechanical connection between the bolster 10 and the door panel metalsupport structure 70.

Reference is made to FIG. 19C, which shows yet another embodiment of ameans to fasten an expansible chamber 57 to the door panel metal supportstructure 70. In this embodiment, the outside wall 12 of an expansiblechamber 57 comprises insert apertures 59 appropriately sized to receivebolster tab inserts 79, which are of an appropriate thickness and sizeto provide the required tensile strength and other desired mechanicalproperties. The insert apertures 59 are positioned in the attachmentportion 61, between the pleats 18 on the outer wall 12, of theexpansible chamber 57 and the connection 71 between the bolster 10 andthe fluid conduit 55 a. Additional frangible fasteners (not shown) maybe used to detachably attach any of the peripheral portions 72 of theouter wall 12 of the bolster, including the expansion pleats 18, to thedoor panel metal support structure 70 while the bolster is in itsuninflated condition. Fasteners within the peripheral portions 72 of thebolster outer wall 12 can be released by inflation of the expansiblechamber 57 so as to not prevent the outer wall 12 from moving relativeto the side of the vehicle during inflation.

The particular attachment means embodied in FIG. 19C comprises fasteningclips 80 that are placed over the bolster tab inserts 79. The fasteningclips 80 can be manufactured separately and then easily affixed to thebolster tab inserts 79 prior to the bolster portion 50 being installedin the vehicle. Upon affixing the required fastening clips 80 to thebolster tab inserts 79, the bolster can be positioned relative to thedoor panel metal support structure 70 and aligned with the predeterminedfastening locations 63 within the structure. With the fastening clips 80properly aligned with the fastening locations 63, pressure can beapplied to the bolster 10 forcing the fastening clips 80 into thefastening locations 63 and creating a snap-fit connection between thebolster 10 and the door panel metal support structure 70. Thisconnection means can be implemented at the appropriate number offastening locations 63 as required to produce the desired strength ofmechanical connection between the bolster 10 and the door panel metalsupport structure 70.

While much of the foregoing description has related to the bolsterportion 50, it will be appreciated that similar attachment means can beused to secure the bolster portion 50 and 52 to door panel metal supportstructure 70 of the door. Alternatively, bolster portion 50 and 52 maybe secured to some other portion of the door, such as the panel 19.

It is optionally possible to have the bolster 10 cover substantially allof the interior surface of the door body 17 b, so that the occupant 13is protected regardless of the region on the door body 17 towards whichthey accelerate. In such an embodiment, first and second bolsterportions 50 and 52 may not be required. For example, the bolster 10could be a contiguous device that is generally C-shaped, extendingabove, below and aft of the armrest 26. Additionally, the bolster 10 maybe configured to cover some or all of the door window 17 a to protectthe occupant from colliding therewith during a crash event. To achieveprotection from the door window 17 a, the bolster 10 would be configuredto expand outwards, and to expand upwards along its top edge.

The armrest 26 itself may be formed as part of the bolster 10. Byforming the bolster 10 integrally with the armrest 26, (e.g., by blowmolding a combined armrest and bolster), assembly of the door 17 issimplified, since only one item (i.e., the combined armrest and bolster)needs to be installed on the door body 28 instead of two separate items.The armrest 26 in this embodiment need not be made to expand when thebolster 10 expands.

Reference is made to FIGS. 5A and 5B, in which the armrest 26 includesthe bolster 10. In this embodiment, the main body 11 of the bolster 10is the structural member of the armrest 26. The main body 11 may befinished in any suitable way to provide a suitable first surface for thearmrest 26. For example, the main body 11 may be textured and may bemade from a coloured polymer. Alternatively, the main body 11 may becovered by a layer of polymeric foam and a skin, such as a vinylcovering.

By incorporating the bolster 10 into the armrest 26, a savings isenjoyed by the vehicle manufacturer relative to providing two separateitems, each of which have an associated cost and each of which wouldhave to be installed on the door 17.

It is alternatively possible that the armrest 26 could act as a housingfor the bolster 10. The armrest 26 could be configured to have a hingedcover that would swing open to provide an opening through which thebolster 10 could expand upwards and out to protect the occupant 13.

Reference is made to FIGS. 6A and 6B, in which the headrest, shown at 28b includes the bolster 10. In this embodiment, the main body 11 of thebolster 10 is also the structural member of the headrest 28 b. Similarlyto the armrest 26 in the embodiment shown in FIGS. 5A and 5B, the mainbody 11 may be finished in any suitable way to provide a suitable firstsurface for the headrest 28 b. For example, the main body 11 may becovered by a layer of polymeric foam and a skin, such as a vinylcovering. The advantages provided by a bolster 10 that replaces thestructural member of the headrest 28 b are similar to those provided bythe bolster 10, which is the structural member of the armrest 26 in theembodiment shown in FIGS. 5A and 5B.

When inflated, the bolster 10 shown in FIGS. 6A and 6B provideadditional deceleration distance for the head of the occupant 13,relative to a standard passive headrest during certain types ofcollision. Additionally, the bolster 10, when inflated, may beconfigured to provide some control over lateral movement of theoccupant's head, by providing a dished forward surface.

Referring to FIGS. 7A and 7B, a combination of two bolsters 10 areprovided. A headrest bolster 10 a cooperates with a neck bolster 10 b toposition the occupant's head and neck and absorb impact energytherefrom. The headrest bolster 10 a may be similar to the headrestbolster 10 shown in FIGS. 6A and 6B. The neck bolster 10 b is providedto occupy, in its inflated form, the generally concave space at the backof the occupant's neck when the occupant's head encounters the inflatedheadrest bolster 10 a. By cooperating together, the headrest and neckbolsters 10 a and 10 b lengthen the deceleration of the occupant's headand neck, thereby reducing the likelihood of injury to the occupant, andin particular reducing the likelihood of whiplash.

Reference is made to FIGS. 8A and 8B, which show two bolsters 10. Whenthe vehicle undergoes certain types of crash event, the occupant 13 isurged forward, and may be urged in such a manner as to slide forwardthrough the shoulder belt, shown at 30 a and through the hip belt, shownat 30 b, towards the foot well (not shown). This is colloquially knownas ‘submarining’. In this embodiment, the two bolsters 10 cooperatetogether to assist in maintaining the occupant 13 in the seat 28 andinhibit submarining of the occupant 13.

The bolsters 10 include a lumbar bolster 10 c and a forward pelvicbolster 10 d. The lumbar bolster 10 c is positioned on the seat'sbackrest, shown at 28 c, and, when inflated, is configured to push thebody-supporting surface of the seat 28 and the occupant's torso forward.

The forward pelvic bolster 10 d is positioned at the forward edge of theseat bottom portion 28 a, and is configured, in its inflated position,to raise the body-supporting surface of the seat 28 and the knees of theoccupant 13 and to cup the pelvic region of the occupant 13 at thejunction of the seat bottom portion 28 a and the backrest 28 c.

Thus, when the occupant 13 is belted in, the lumbar bolster 10 c and theforward pelvic bolster 10 d cooperate to ‘fold’ the occupant about thepelvic region. This folding of the occupant 13 impedes the occupant fromsliding down and forward through the shoulder and hip belts 30 a and 30b towards the foot well (not shown) during a crash event.

It is possible to provide either the lumbar bolster 10 c alone or theforward pelvic bolster 10 d alone to assist in inhibiting submarininginstead of providing two bolsters 10 c and 10 d together. However,providing the two bolsters 10 c and 10 d together is preferable.

Instead of rupturing a continuous seat surface during inflation, themain bodies 11 of the lumbar and forward pelvic bolsters 10 c and 10 dmay be finished in such a way as to form part of the first surfaces ofthe seat 28. For example, the main body 11 of each may be covered with asuitable layer of polymer foam and with a skin of any suitable material,such as leather or cloth. The skin on the main body 11 would be aseparate panel from the rest of the seating surfaces of the seat bottomportion 28 a and the backrest 28 c. Thus, when either or both of thelumbar and forward pelvic bolsters 10 c and 10 d deploy, they do notrupture the seat covering that makes up the rest of the seating surface.Alternatively, the bolsters 10 c and 10 d may be buried within the seatbottom portion 28 a and the backrest 28 c, under a layer of foam thatmay be contiguous, and under a contiguous skin.

Reference is made to FIGS. 9A and 9B, which show an outside pelvicbolster 10, which assists in decelerating the pelvic region of theoccupant 13 during certain types of crash event. As with the bolsters 10c and 10 d shown in FIGS. 8A and 8B, the main body 11 of the bolster 10in FIGS. 9A and 9B, may be covered with a suitable layer of polymer foamand with a suitable skin, which may be separate from the skin on therest of the seating surface of the backrest 28 c. It is optionallypossible for the bolster 10 to extend upwards farther along the backrest28 c, or to be positioned farther up along the backrest 28 c to controlthe deceleration of other regions on the occupant's torso in additionto, or instead of, controlling the deceleration of the pelvic region.

Reference is made to FIGS. 10A and 10B, which show the bolster 10positioned on the rear face of the backrest 28 c. The bolster 10 deploysto protect the legs of the occupant (not shown) positioned in the seat(not shown) behind the seat 28.

Reference is made to FIGS. 11A and 11B, which show a bolster 10 mountedon the floor pan of the vehicle 15. The bolster 10 deploys to controlthe position of the feet of the occupant 13 during certain types ofcrash event. The bolster 10 supports the feet of the occupant 13 fromunderneath via a foot-supporting surface that is displaced by inflationof the bolster 10.

The main body 11 of the bolster 10 may be finished with a covering layerof carpeting and may thus form part of the floor carpeting in thevehicle. Additionally or alternatively, the main body 11 may have aseries of drain channels 31 formed thereon to drain water and snow awayfrom the feet of the occupant 13 if the occupant's shoes are wet orsnowy.

Referring to FIGS. 12A and 12B, the bolster 10 may be positioned in partin the floor pan of the vehicle and in part in the toe pan. The bolster10 may include the carpet covering and/or the drain channels 31 that areoptionally provided on the bolster 10 shown in FIGS. 11A and 11B.

Referring to FIGS. 13A, 13B and 13C, one or more bolster systems 34 maybe positioned about one or more rollover protection bars 32 which may beprovided on the vehicle. Each bolster system 34 surrounds the associatedrollover protection bar 32 and slow the deceleration of a vehicleoccupant 13 prior to the occupant 13 encountering the rolloverprotection bar 32 during certain types of crash event. Referring to FIG.13C, each bolster system 34 may include first and second bolsters 10,which together cover a rollover protection bar 32 circumferentially.Each bolster 10 includes a hollow main body 11, which is shaped to havea radially inner surface 36 which contacts and engages rolloverprotection bar 32, and which has a radially outer surface 38, in whichthere are a plurality of pleats 18. The pleats 18 permit the bolster 10to expand radially when inflated.

It is alternatively possible for the pleats 18 to be omitted from themain body 11, and to cause expansion of the main body 11 by plasticdeformation that occurs as a result of the introduction of pressurizedgas into the main body 11.

The bolsters 10 may be housed in a covering layer 40. The covering layer40 holds the bolsters 10 together about the rollover protection bar 32.Additionally, the covering layer 40 hides the pleats 18 on the bolsters10, if pleats 18 are present. The covering layer 40 may be a tubularpiece that is open at its ends and that has a longitudinally extendingopening 42. The bolsters 10 may be introduced into the covering layer 40through the open ends or by stretching open the longitudinal opening 42.The covering layer 42 is fit over the rollover bar 32 by stretching openthe opening 42. The covering layer 40 may include one or more connectors44 to permit the opening 42 to be held closed.

It is alternatively possible to have a single bolster 10, which is heldwithin the covering layer 40. The single bolster 10 would have alongitudinally extending opening, and could be made to be flexibleenough to open around the rollover bar 32.

When pressurized gas is introduced into the bolsters 10 during bolsterdeployment, the bolsters 10 expand radially outwards and force thecovering layer 40 to either stretch radially outwardly or to open at theopening 42.

Reference is made to FIGS. 14A and 14B, which show the bolster 10positioned on the vehicle roof, shown at 46. The bolster 10 deploys toextend downwards to assist in controlling the deceleration of theoccupant 13 towards the door window 17 a and in particular towards thejunction between the door 17 and the roof 46. The main body 11 of thebolster 10 may be finished to as to directly act as the first surface,or may be covered by a suitable piece of material that acts as the firstsurface. Alternatively, the main body 11 may be hidden from view by theheadliner.

It is optionally possible for the bolster 10 to extend farther downwardsthan is shown in FIG. 14B, so that it can protect the head of theoccupant from hitting relatively lower regions on the door window 17 a.

Reference is made to FIGS. 14A and 14B, which show the bolster 10positioned on the vehicle's B-pillar, shown at 48. The bolster 10 andmay be configured to extend forwardly, rearwardly and inwardly away fromthe B-pillar.

It is optionally possible for the bolster 10 to be positioned on any ofthe A, B, C or D pillars (if present) in the vehicle, to protect vehicleoccupants in situations where there is a risk of collision with thoseregions in the vehicle.

The main body 11 may be finished or covered suitably to act as the firstsurface in pillar-mounted embodiments, such as the embodiment shown inFIGS. 15A and 15B.

Referring to FIG. 20A, a headrest 28 b in accordance with a furtherembodiment of the invention is shown in a perspective view. The headrest28 b comprises a bolster 10 mounted on a headrest mounting bracket 87.The bolster 10 comprises a rear wall 86, side walls 16, and relativelynon-expansible front wall 85 and front inside walls 85 a enclosing anexpansible hollow interior 57. The bolster 10 further comprises aninflator 54, which is attached to the headrest mounting bracket 87, andan inflation aperture 90 that is integral to the front wall 85 of thebolster 10. The inflator 54 is located outside of expansible hollowinterior 57 of the bolster 10. The headrest mounting bracket 87positions the bolster 10 in an appropriate location relative to thevehicle seat back 28 d (shown in FIG. 21A). The headrest mountingbracket 87 is rigidly fixed to the vehicle seat back 28 d by anappropriate, secure fastening means (not shown). The front wall 85 ofthe bolster 10 is relatively non-expansible and comprises an attachmentportion 61 that is rigidly attached to the headrest mounting bracket 87using an appropriate fastening means (not shown). The rigid attachmentportion 61 connecting the relatively non-expansible front wall 85 andthe headrest mounting bracket 87 is required to hold the bolster 10 inplace during routine operation of the vehicle and to ensure that thebolster 10 remains in place during inflation.

The side walls 16 of the bolster 10 comprise expansion pleats 18. Thenumber and design of the pleats may be used to control the direction andmagnitude of the expansion of the expansible hollow interior 57 of thebolster 10. During inflation, the front wall 85 and the front insidewalls 85 a remain in place while the rear wall 86 and the side walls 16extend away from the headrest support bracket 87 and toward the back ofthe vehicle. The front inside walls 85 a are designed to allow for thebolster 10 to extend in the forward direction but to prevent expansionby the bolster 10 in the inward direction, toward the head of thevehicle occupant to prevent injury.

Referring to FIG. 20B, the headrest 28 b as shown in FIG. 20A is shownin an exploded view. This figure also shows a portion of non-expansiblepadding material 88 designed to provide static support to the head ofthe vehicle occupant 13. The non-expansible padding 88 is rigidlyattached to the headrest mounting bracket 87 by an appropriateattachment means (not shown) and is designed to fill the cavity boundedby the bolster 10 front 85 and front inside 85 a walls. An externalheadrest cover 89 is also shown in this figure. The external headrestcover 89 is installed on an assembled headrest 28 b and may be finishedappropriately to act as a first surface. Referring to FIG. 20C, aheadrest 28 b as shown in FIGS. 20A and 20B is shown with the headrestcover 89 in place and headrest mounting bracket 87 visible.

Referring to FIG. 20D, the headrest 28 b as shown in FIGS. 20A, 20B and20C is shown in an inflated configuration. This figure shows therelative displacement of the rear 86 and side walls 16 of the bolster 10due to the expansion of the pleats 18 (shown in FIG. 20A) and expansiblehollow interior 57. This figure also shows the non-expansible paddingmaterial 88, front wall 85, and front inside walls 85 a remaining inplace relative to the headrest mounting bracket 87 after inflation.

Referring to FIG. 21A, a seat back 28 d bolster 10 is shown inaccordance with a further embodiment of the invention. A seat 28 isshown comprising a seat bottom portion 28 a, a headrest portion 28 b,and a seat back portion 28 d. The seat back portion 28 d furthercomprises an attachment portion 61 and a peripheral portion 72. Theattachment portion 61 and peripheral portion 72 are designed toappropriately mount a bolster 10 which is deployed to protect vehiclepassengers riding in the backseat of the vehicle. This figure also showsa bolster 10 to be affixed to the seat back 28 d. The bolster 10 furthercomprises a occupant side wall 86, that forms part of the boundary of anexpansible hollow interior 57, and an inflator module 54 that is used toinflate the expansible hollow interior 57 of the bolster 10.

Referring to FIG. 21B, the bolster 10 as shown in FIG. 21A is showncomprising an occupant side wall 86, side walls 16, and a seat side wall85 which serve to bound an expansible hollow interior 57. The seat sidewall 85 of the bolster 10 further comprises an attachment portion 61 anda peripheral portion 72. The attachment portion 61 of the bolster 10 isrigidly attached to the seat back 28 d (as shown in FIG. 21A) by anappropriate fastening means (not shown). The attachment means is suchthat the portion of the seat side wall 85 of the bolster 10 within theattachment portion 61 of the bolster is held in place during normaloperation and inflation of the bolster 10. Portions of the bolster seatside wall 85 contained within the attachment portion 61 of the bolster10 cannot move relative to the seat back attachment portion (designatedusing reference numeral 61 in FIG. 21A). Peripheral portions 72 of thebolster seat side wall 85 may be attached to the seat back 28 d (notshown) by appropriate frangible fastening means (not shown) such thatthe bolster 10 is held in place during normal operation of the vehiclebut also such that the attachment means is released by the inflation ofthe expansible hollow interior of the bolster 10 allowing the seat sidewall 85 to move away from the seat back 28 d and toward the back of thevehicle. The bolster seat side wall 85 further comprises expansionpleats 18 that allow for the inflation of the expansive hollow interior57 of the bolster 10 and can also be designed appropriately to controlthe extent and direction of expansion. The bolster 10 is shown in anun-inflated configuration.

The bolster 10 shown in FIG. 21B further comprises an integral inflationaperture 90 that accepts an inflator module 54 via an appropriatecoupling means (not shown).

Referring to FIG. 21C, a sectioned view of the bolster 10 shown in FIG.21B shows the expansion pleats 18 and peripheral portion 72 of the seatside wall 85 of the bolster 10. This figure also shows a sectioned viewof the occupant side wall 86 and expansible hollow interior 57 of thebolster 10 in its un-inflated configuration.

Referring to FIG. 21D, a perspective view of a seat 28 and seat back 28d shows the relative position of the bolster 10 shown in FIGS. 21A and21B as attached to the seat back 28 d in an un-inflated configuration.The occupant side wall 86 of the expansible hollow interior 57 of thebolster 10 may be suitably covered or finished to serve as a firstsurface. During inflation of the expansible hollow interior 57, theoccupant side wall 86 of the bolster 10 will move away from the seatback 28 d and toward the back of the vehicle.

Referring to FIG. 21E, a perspective view of a seat 28 and seat back 28d shows the relative position of the bolster 10 shown in FIGS. 21A, 21B,and 21D as attached to the seat back 28 d in an inflated configuration.This figure shows the relative displacement away from seat back 28 d ofthe occupant side wall 86 and peripheral portions 72 of the seat sidewall 85 of the bolster 10 during the inflation of the expansible hollowinterior 57. The expansion pleats 18 are shown in their extendedpositions. The attachments between the seat side wall 85 and the seatback 28 d contained within the attachment portion 61 remain intactduring expansion, and this portion of the seat side wall 85 does notextend away from the seat back 28 d.

Several of the bolster embodiments shown in the Figures are madeoversized so that they protect a relatively wide range of sizes ofvehicle occupant and to protect occupants over a relatively wide rangeof seat adjustment positions in the vehicle. In other words, thebolsters 10 may be sized to protect an occupant whether his/her seat isadjustment to its rearmost available position or its forwardmostposition.

As will be apparent to persons skilled in the art, various modificationsand adaptations of the apparatus described above may be made withoutdeparture from the present invention, the scope of which is defined inthe appended claims.

The invention claimed is:
 1. An inflatable bolster for use in apassenger compartment of a vehicle, the inflatable bolster comprising: ahollow body including an outside wall configured to face a matingsurface of the vehicle, the outside wall being provided with one or moreintegral bolster mounting tabs formed as part of the outside wall, andan inside wall opposite the outside wall and configured to face aninterior of the vehicle; an inflator for injecting a pressurized fluidinto the hollow body to thereby inflate the hollow body, the inflatorbeing mounted to the hollow body; and attachment means for attaching thehollow body to the mating surface, the attachment means comprising afastening clip mounted on each of the one or more integral bolstermounting tabs, wherein the fastening clip is configured to provide asnap-fit connection of the hollow body to the mating surface of thevehicle.
 2. The inflatable bolster of claim 1, wherein the fasteningclip is attached to the integral bolster mounting tab using a rivet. 3.An inflatable bolster for use in a passenger compartment of a vehicle,the inflatable bolster comprising: a polymeric hollow body including anoutside wall configured to face a mating surface of the vehicle, theoutside wall having formed therein one or more insert apertures, and aninside wall opposite the outside wall and configured to face an interiorof the vehicle; an inflator for injecting a pressurized fluid into thehollow body to thereby inflate the hollow body, the inflator beingmounted to the hollow body; and attachment means for attaching thehollow body to the mating surface, the attachment means comprising amounting insert positioned in each of the one or more insert apertures,wherein the mounting insert is configured for mechanical attachment ofthe hollow body to the mating surface of the vehicle.
 4. The inflatablebolster of claim 3, wherein the mounting insert is a threaded studinsert configured to cooperate with a fastening nut to secure the hollowbody to the mating surface through mechanical compression.
 5. Theinflatable bolster of claim 3, wherein the mounting insert is a tabinsert configured to cooperate with a fastening clip to secure thehollow body to the mating surface through a mechanical snap-fitconnection.